Thermomechanical Analysis of Wheel-Rail Contact: Modeling, Validation, and Application

The generation of frictional heat at the wheel-rail interface is a critical factor during train operations, especially during acceleration and braking. High slip ratios can lead to substantial thermal loading due to the rapid accumulation of thermal energy, resulting in significant temperature increases in the contact area. This thermal loading is known to accelerate wear, induce plastic deformation, and cause thermal fatigue in wheel and rail materials. Additionally, high contact temperatures around 720 °C may induce microstructural transformations in the material, leading to the formation of the white etching layer (WEL), which includes brittle martensite and makes the material more prone to cracking. These wheel-rail interface deteriorations increase maintenance costs and impact the operational safety of trains. Therefore, it is vital to investigate the wheel-rail friction-induced temperature and its effects on wheel/rail damage. The aim of this research is to better understand the thermomechanical behavior of the wheel-rail system. Three objectives are accomplished to reach this goal: 1) establish numerical models and experimental setups to accurately assess the thermomechanical behavior of the wheel-rail contact system; 2) reliably validate the thermomechanical contact model by accurately measuring the wheel-rail contact temperature, especially under the high slip ratio conditions; 3) improve the understanding of the generation and development of thermomechanical damage, e.g., polygonal wear and a “wheel flat”…